TOYOTA AVENSIS 2005 Service Repair Manual

A57099
A56702
17±26
± LUBRICATIONOIL PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(f) Install the oil pump with the 9 bolts.
Torque: 31 N
m (320 kgf
cm, 23 ft
lbf)
(g) Measure the oil pump rotating torque.
(1) Check that the pump rotates smoothly without
noise.
(2) Using a torque wrench, check the pump rotating
torque.
Rotating torque: 3.0 N
m (31 kgf
cm, 27 in.
lbf) or less
37. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
38. INSTALL OIL PAN SUB±ASSY
(a) Remove any old packing (FIPG) and be careful not to
drop any oil on the contact surfaces of the No. 1 oil pan,
the cylinder block and the oil pump and the rear oil seal
retainer.
(1) Using a razor blade and gasket scraper, remove all
the old packing from the gasket surfaces.
(2) Thoroughly clean all components to remove all the
loose material.
(3) Using a non±residue solvent, clean both the sealing
surfaces.

A56703
Seal Width
4 to 7 mm
A
AB
B
A56697
AA
A
A
AA B B DBBB
BC C
C CC
CCDD
A56696
± LUBRICATIONOIL PUMP ASSY (1CD±FTV)
17±27
AVENSIS REPAIR MANUAL (RM1018E)
(b) Apply a seal packing to the No. 1 oil pan as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
(1) Install a nozzle that has been cut to a 4 to 7 mm
(0.16 to 0.28 in.) opening.
(2) Parts must be set within 3 minutes and assembled
within 15 minutes of application. Otherwise the ma-
terial must be removed and reapplied.
(3) Immediately remove nozzle from the tube and rein-
stall the cap.
(c) Install the oil pan with the 19 bolts and 3 nuts.
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for bolt A
21 N
m (214 kgf
cm, 15 ft
lbf) for bolt B
11 N
m (112 kgf
cm, 8 ft
lbf) for bolt C
12 N
m (122 kgf
cm, 9 ft
lbf) for nut D
39. INSTALL OIL PAN INSULATOR
(a) Install the oil pan insulator with the bolt.
Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
40. INSTALL OIL STRAINER SUB±ASSY
(a) Install a new gasket and the oil strainer with the 2 bolts
and 2 nuts.
Torque:
21 N
m (209 kgf
cm, 15 ft
lbf) for bolt
13 N
m (135 kgf
cm, 10 ft
lbf) for nut
41. INSTALL OIL PAN SUB±ASSY NO.2
(a) Remove any old packing and be careful not to drop any
oil on the contact surfaces of the No. 1 and No. 2 oil pans.
(1) Using a razor blade and gasket scraper, remove all
the old packing from the gasket surfaces.
(2) Thoroughly clean all components to remove all the
loose material.

A56704
Seal Width
4 to 7 mm
A
B B
A
A79173New O±ring
17±28
±
LUBRICATION OIL PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(3)Using a non±residue solvent, clean both the sealing surfaces.
NOTICE:
Do not use a solvent, which will affect the painted surfaces.
(b)Apply a seal packing to the oil pan as shown in the illustra- tion.
Seal packing: Part No. 08826±00080 or equivalent
(1)Install a nozzle that has been cut to a 4 to 7 mm
(0.16 to 0.28 in.) opening.
(2)Parts must be set within 3 minutes and assembled within 15 minutes of application. Otherwise the ma-
terial must be removed and reapplied.
(3)Immediately remove nozzle from the tube and rein- stall the cap.
(c)Install the oil pan with the 17 bolts and 2 nuts. Tighten the
bolts and nuts uniformly in several steps.
Torque: 12 N m (119 kgf cm, 9ft lbf)
42.INSTALL ENGINE OIL LEVEL SENSOR Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
43.INSTALL OIL LEVEL GAGE GUIDE
(a)Install a new O±ring to the oil level gage guide.
(b)Apply engine oil to the O±ring.
(c)Push in the oil level gage guide end into the guide hole of the No. 1 oil pan.
(d)Install the oil level gage guide with the bolt. Torque: 18 N m (184 kgf cm, 13 ft lbf)
(e)Apply engine oil to the O±ring on the oil level gage.
(f)Install the oil level gage.
44.INSTALL V±RIBBED BELT TENSIONER ASSY Torque: 31 N m (320 kgf cm,23 ft lbf)
45.INSTALL TIMING BELT IDLER SUB±ASSY NO.1
Torque: 35 N m (357 kgf cm,26 ft lbf)
46.INSTALL GENERATOR ASSY(See page 19±29)

SST
A09583
Inward
Angle Sensor
±
LUBRICATION OIL PUMP ASSY(1CD±FTV)
17±29
AVENSIS REPAIR MANUAL (RM1018E)
47.INSTALL CRANKSHAFT TIMING PULLEY
(a)Align the keyway of the timing pulley with the key located
on the camshaft, slide the pulley into place.
(b)Using SST and a hammer, tap in the timing pulley with the angle sensor facing inward.
SST09223±46011
48.INSTALL TIMING BELT IDLER SUB±ASSY NO.2 Torque: 47 N
m (479 kgf
cm,35 ft
lbf)
49.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307) SST 09960±10010 (09962±01000, 09963±01000)
50.INSTALL TIMING BELT(See page 14±307)
51.CHECK VALVE TIMING(See page 14±307)
52.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
53.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
54.INSTALL TIMING BELT GUIDE(See page 14±307)
55.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
56.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
57.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
58. INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
59. INSTALL IDLER PULLEY SUB±ASSY
60.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
61. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
62.INSTALL INJECTOR DRIVER (See page 14±307)
63. INSTALL ENGINE COVER NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
64. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
65.ADD ENGINE OIL(See page 17±30)
66. CHECK FOR ENGINE OIL LEAKS

17045±03
A56466
Recommended Viscosity (SAE)
BEFORE NEXT OIL CHANGE TEMPERATURE RANGE ANTICiPATED416 2738
0 20 40 60 80 100 ±29
±20±18 ±7
C

F20 W ± 50
15 W ± 40
10 W ± 30
5 W ± 30 PREFERRED
B14332
Oil Pressure Switch
B14333
Oil Pressure Gauge 17±20
± LUBRICATIONLUBRICATION SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
LUBRICATION SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
1. CHECK ENGINE OIL LEVEL
(a) After warm up the engine and then 5 minutes after the engine stop, oil level should be between the
low level and full level marks of the dipstick.
If low, check for leakage and add oil up to the full level mark.
NOTICE:
Do not fill with engine oil above the full level mark.
2. CHECK ENGINE OIL QUALITY
(a) Check the oil for deterioration, entry of water, discoloring
or thinning.
If the quality is visibly poor, replace the oil.
Oil grade:
Use ACEA B1, API grade CF ± 4 or CF
(You may also use API CE or CD)
SAE 5W ± 30 is the best choice for your vehicle, for
good fuel economy, and good starting in cold weath-
er.
3. REMOVE OIL PRESSURE SWITCH ASSY
(a) Disconnect the oil pressure switch connector.
(b) Using a deep socket wrench 24mm, remove the oil pres-
sure switch.
4. INSTALL OIL PRESSURE GAUGE
(a) Install the oil pressure gauge.
5. WARM UP ENGINE

P13638
Adhesive
± LUBRICATIONLUBRICATION SYSTEM (1CD±FTV)
17±21
AVENSIS REPAIR MANUAL (RM1018E)
6. CHECK OIL PRESSURE
Oil pressure:
At idle29 kPa (0.3 kgf/cm2, 4.3 psi) or more
At 4,500 rpm245 to 588 kPa (2.5 to 6.0 kgf/cm2, 36 to 85 psi) or more
7. REMOVE OIL PRESSURE GAUGE
8. INSTALL OIL PRESSURE SWITCH ASSY
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833 ± 00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a deep socket wrench 24mm, install the oil pres-
sure switch.
Torque: 15 N
m (153 kgf
cm, 11 ft
lbf)
NOTICE:
Do not start the engine within 1 hour after the installation.
(c) Connect the oil pressure switch connector.
9. START ENGINE AND CHECK FOR LEAKS

170FV±01
A56222
A56223
± LUBRICATIONOIL FILTER SUB±ASSY (1AZ±FSE)
17±19
AVENSIS REPAIR MANUAL (RM1018E)
OIL FILTER SUB±ASSY (1AZ±FSE)
REPLACEMENT
CAUTION:

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from
the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains po-
tentially harmful contaminants which may cause skin cancer.

Exercise caution in order to minimize the length and frequency of contact of your skin to used
oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use
water±less hand cleaner to remove any used engine oil. Do not use gasoline, thinners, or sol-
vents.

In order to preserve the environment, used oil and used oil filter must be disposed of only at
designated disposal sites.
1. REMOVE ENGINE UNDER COVER RH
2. DRAIN ENGINE OIL
(a) Install a new gasket and drain plug after draining engine oil.
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)
3. REMOVE OIL FILTER SUB±ASSY
(a) Using SST, remove the oil filter.
SST 09228±06501
4. INSTALL OIL FILTER SUB±ASSY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the
gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn.
SST 09228±06501
5. ADD ENGINE OIL
(a) Fill with fresh engine oil.
Capacity:
Drain and refill w/ Oil filter change 4.2 liters (4.4 US qts, 3.7 lmp. qts)
Drain and refill w/o Oil filter change 4.0 liters (4.2 US qts, 3.5 lmp. qts)
Dry fill 4.9 liters (5.2 US qts, 4.3 lmp. qts)
(b) Install the oil filler cap.
6. INSPECT OIL LEAK

170FX±01
A77339
±
LUBRICATION OIL PUMP ASSY(1AZ±FSE)
17±15
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1AZ±FSE)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±30)
2.REMOVE FRONT WHEEL RH
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN ENGINE OIL
(a)Install a new gasket and drain plug after draining engine oil.
Torque: 25 N
m (250 kgf
cm,18 ft
lbf)
8.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the engine cover No. 1.
9.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
10.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±33)
11.SEPARATE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
12.REMOVE FUEL PUMP ASSY (See page 11±52)
13.REMOVE FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
14.REMOVE GENERATOR ASSY (See page 19±20)
15.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
16.SEPARATE VANE PUMP ASSY (See page 14±222)
17.SEPARATE RETURN TUBE SUB±ASSY (See page 14±222)
18. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE) (See page 14±222)
19. SEPARATE VANE PUMP OIL RESERVOIR ASSY
20.REMOVE OIL RESERVOIR BRACKET NO.1 (See page 14±222)
21. SEPARATE ENGINE WIRE
22.REMOVE COOLER BRACKET (LHD STEERING POSITION TYPE) (See page 14±222)
23. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(a) Remove a bolt and the engine service cover bracket RH.
24. REMOVE IGNITION COIL ASSY
(a) Remove 4 bolts and the ignition coils.
25.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
26.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±222)
27.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±222)
28.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±222)

A64641
A00019
B11673
17±16
±
LUBRICATION OIL PUMP ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
29.REMOVE CRANKSHAFT PULLEY (See page 14±222) SST09213±54015 (91651±60855), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05021)
30.REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14±139)
31.REMOVE CRANKSHAFT POSITION SENSOR (See page 18±17) 32.REMOVE OIL PAN SUB±ASSY
(a)Remove 12 bolts and 2 nuts.
(b)Insert the blade of SST between the crank case, timingchain cover and oil pan, cut off applied sealer and remove
the oil pan.
SST09032±00100
NOTICE:
Be careful not to damage the contact surface of timing
chain cover, crank case and oil pan.
33.REMOVE V±RIBBED BELT TENSIONER ASSY (See page 14±139)
34.REMOVE TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
35.REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
36.REMOVE CHAIN TENSIONER SLIPPER
37.REMOVE CHAIN VIBRATION DAMPER NO.1
38.REMOVE TIMING CHAIN GUIDE (See page 14±139)
39.REMOVE CHAIN SUB±ASSY
40.REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
41.REMOVE NO.2 CHAIN SUB±ASSY (See page 14±139) 42.REMOVE OIL PUMP ASSY
(a)Remove 3 bolts, the oil pump and gasket.
43.INSTALL OIL PUMP ASSY
(a)Install a new gasket and oil pump with 3 bolts. Torque: 19 N
m (195 kgf
cm,15 ft
lbf)
44.INSTALL NO.2 CHAIN SUB±ASSY (See page 14±139)
45. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

A77392Seal Packing6mm
A64641
±
LUBRICATION OIL PUMP ASSY(1AZ±FSE)
17±17
AVENSIS REPAIR MANUAL (RM1018E)
46.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
47.INSTALL CHAIN VIBRATION DAMPER NO.1
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
48.INSTALL CHAIN SUB±ASSY (See page 14±139)
49.INSTALL TIMING CHAIN GUIDE Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
50.INSTALL CHAIN TENSIONER SLIPPER (See page 14±139)
51.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±139)
52.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
53.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±139)
54.INSTALL OIL PAN SUB±ASSY
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not start the engine within 2 hours after installing.
(a)Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder
block and oil pan.
(b)Apply seal packing in the shape of bead (Diameter 3 to 4
mm (0.157 in.)) as shown in the illustration, and install the
oil pan.
Seal Packing: Part No. 08826 ± 00080 or equivalent
(c)Insert the oil pan with 12 bolts and 2 nuts. Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
55.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
56.INSTALL CRANKSHAFT PULLEY (See page 14±139) SST 09213±54015 (91651±60855), 09330±00021
57. INSTALL CHAIN TENSIONER ASSY NO.1
58. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
59.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
60.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
61. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
62. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
63. INSTALL ENGINE WIRE Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)